Methods for making flexible containers and associated products

ABSTRACT

Disclosed is a method for making a flexible container. The method implements an injection mold having a collapsible core that expands/moves to define the apertures and, in some embodiments, holds a flexible film in place during the injection mold process and collapses/moves back post-injection molding to allow for the flexible container to be readily removed from the die. In addition, the method described includes a post-injection molding anneal process that is implemented to allow the flexible film to shrink so as to provide for form-fitting of the film to the molded portion of the container.

FIELD

The proposed invention is a method for making flexible containers havinga molded portion and a flexible film portion and products resulting fromthe method.

BACKGROUND

Typically, consumer packaging, for household products, such as laundrydetergent or the like, takes on the form of cardboard cartons, flexiblebags and/or molded containers (e.g. tubs, buckets or the like).

Traditional molded containers are formed by an injection molding processfrom a polymeric/plastic material, such as polypropylene, polyethyleneor the like. However, due to the amount of plastic material required,such molded containers tend to be heavier in weight and/or costlier toproduce than other packaging options.

Recently, flexible containers have been introduced that include both amolded portion and a flexible portion. The flexible portion, typically alaminate film or the like, replaces an area of the container that wouldotherwise be formed of the molded plastic material. The flexible filmportion is applied during the injection molding process and results in acontainer having significantly reduced weight. Additionally, theflexible portion is typically configured to include a printed label thatincludes graphics, such as product logo, product information and thelike, thus, eliminating the need to apply a separate label to thecontainer after the injection molding process; thereby reducing handlingand secondary operations.

However, when such flexible film portions are applied during theinjection molding process, problems have been apparent. The molded(i.e., crystalline plastic) portion tends to shrink in size as it coolsduring the injection molding process, while the laminate films used forthe flexible portion do not experience the same shrinking phenomena. Asa result, in many desired configurations of the flexible container, theflexible portion will appear loose or oversized as a result of beingapplied during the injection molding process.

Moreover, problems result from the configuration of injection moldsrequired to form a molded portion having an aperture over which theflexible film portion is applied. In this regard, the portion of themold that forms the aperture in the molded portion results in difficultywith being able to remove the flexible container from the mold (i.e.,the flexible portion tends to stick to the core of the male die).

Therefore, a need exists to improve upon the method for making flexiblecontainers. The desired method should result in a flexible container inwhich the flexible portion is form-fitted to the molded portion (i.e.,the flexible portion does not appear oversized or loosely fit about themolded portion). In addition, the desired method should provide for theflexible containers to be readily removed from the injection molds, soas to eliminate problems associated with the flexible container stickingto the mold core post-injection mold.

BRIEF SUMMARY

The object of the proposed new art is to provide a method for making aflexible container comprising an injection molded part with at least oneaperture and at least one flexible film that is affixed to theboundaries of the aperture(s) so as to define a container. The methodincludes a die having a collapsible core (i.e., a movable portion of themale die) that expands/moves to hold the film in place prior toinjecting the container material and collapses/moves back post-curing ofthe container material to allow for the flexible container to be readilyremoved from the die. In addition, the method includes a post-injectionmolding anneal process that is implemented to allow the flexible film toshrink so as to provide for form-fitting of the film to the moldedportion of the container.

Specific embodiments of the invention are defined by a method for makinga flexible container. The method includes providing for an injectionmold comprising a male die having a central axis and a correspondingfemale die and inserting the male die into the female die. The insertionof the male die into the female die defines a space there between. Themethod further includes moving or otherwise expanding a moveable portionof the male die away from the central axis to thereby reduce a volume ofthe space. Further, the method includes injecting a container materialin the space and curing the container material to create a molded parthaving at least one aperture. In addition, the method includes moving orotherwise collapsing the movable portion of the male die towards thecentral axis to thereby increase the volume of space, withdrawing themale die from the female die and removing the container from theinjection mold. Additionally, the method includes adhering at least onefilm to the molded part along a perimeter of the one or more apertures.Lastly, the method includes annealing the container at a predeterminedtemperature and for a predetermined dwell time to thereby shrink thefilm to form-fit the container.

In specific embodiments of the invention adhering the film to the moldedpart along a perimeter of the apertures is accomplished by disposing thefilm in the female die prior to inserting the male die into the femaledie, such that the curing of the container material additionallyprovides for adhering the film to the molded part along a perimeter ofthe apertures. In such embodiments of the method, moving the movablepart of the male die away from the central axis further serve to holdthe film in place during the injection and cure process. In relatedembodiments of the method, disposing the film in the female die furtherincludes providing for the film comprised of a layered laminate ofpolypropylene, wherein a back layer of the film comprises atemperature-sensitive polymer that adheres to the container materialduring the curing of the container material.

In specific embodiments of the method the film that is adhered to themolded part has a predetermined axial grain orientation to therebyaffect shrinkage in a desired axial direction during annealing. In suchembodiments of the method, the grain orientation is orientation may bepredetermined based one or more of (1) a type of film used, and/or (2) ageometry of the container and/or the at least one aperture.

In other specific embodiments of the method injecting a containermaterial in the space there between further includes injecting thecontainer material in the space, wherein the container material is oneof polypropylene or polyethylene. Additionally, in further embodimentsof the method curing the container material further comprises curing thecontainer material at a predetermined temperature in a range of 300 to525 degrees Fahrenheit.

Moreover, in other specific embodiments of the method moving the movableportion of the male die away from the central axis, further includesclosing the injection mold to affect mechanical movement of the movableportion of the male die away from the central axis and moving themovable portion of the male die towards the central axis, furtherincludes opening the injection mold to affect mechanical movement of themovable portion of the male die towards the central axis.

In additional embodiments of the method, annealing the container at apredetermined temperature and for a predetermined dwell time furtherincludes selecting the predetermined temperature and the predetermineddwell time based on at least one of (1) a size of the container, and (2)a thickness of the film.

Another method for making a flexible container defines other embodimentsof the invention. The method includes providing for an injection moldincluding a male die having a central axis and a corresponding femaledie and disposing a film in the female die. The method further includesinserting the male die into the female die to thereby define a spacebetween the male die and the female die and moving a movable portion ofthe male die away from the central axis to thereby reduce a volume ofthe space and hold the film in place. In addition, the method includesinjecting a container material in the space to create a container havingat least one aperture and curing the container material, such thatcuring the container material provides for adhering the film to thecontainer material over the at least one aperture. Additionally, themethod includes moving the movable portion of the male die towards thecentral axis to thereby increase the volume of the space, withdrawingthe male die from the female die and removing the container from themale die. Further, the method includes subsequently annealing thecontainer at a predetermined temperature and for a predetermined dwelltime to thereby shrink the film to form-fit the container.

Still further embodiments of the invention are defined by a method formaking a molded part. The method includes providing for an injectionmold including a male die having a central axis and a correspondingfemale die and inserting the male die into the female die to define aspace between the male die and the female die. The method furtherincludes moving a movable portion of the male die away from the centralaxis to thereby reduce a volume of the space, injecting a containermaterial in the space and curing the container material to create amolded part having at least one aperture. The moving of the movable ofthe male die away from central axis defines the at least one aperture.Additionally, the method includes moving the movable portion of the maledie towards the central axis to thereby increase the volume of thespace, withdrawing the male die from the female die, and removing themolded part from the injection mold. The moving of the movable portionof the male die towards the central axis assists in removing the moldedpart from the injection mold.

The above description provides exemplary applications. While there arecountless other applications and types of methods for making theflexible container.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the accompanying drawings, where:

FIG. 1 provides schematic diagrams of one example of a molded part, aflexible film (e.g., pre-cut label) and flexible container comprised ofthe molded part and flexible film, in accordance with embodiments of thepresent invention;

FIG. 2 is a flow diagram of a method for making a flexible container, inaccordance with embodiments of the present invention; and

FIGS. 3 and 4 provide a perspective view of one example of the male dieof an injection mold highlighting the collapsible core, in accordancewith embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Described below in detail are methods for making a flexible containerthat includes an injection molded part with at least one aperture and atleast one flexible film that is affixed to the boundaries of theaperture(s) so as to define a container, in accordance with embodimentsof the present invention. In addition to the methods herein described,embodiments of the invention include products (i.e., flexiblecontainers) resulting from the method described.

The methods herein described implement an injection mold having acollapsible core that expands/moves to define the apertures and, in someembodiments, hold the flexible film in place during the injection moldprocess and collapses/moves back post-injection molding process to allowfor the flexible container to be readily removed from the die.

In addition, the method includes a post-injection molding anneal processthat is implemented to allow the flexible film to shrink so as toprovide for form-fitting of the film to the molded portion of thecontainer. As previously discussed, curing the molded portion of theflexible container during the injection molding process results in adegree of shrinkage to the molded portion, however; the curing does notimpart shrinkage in the flexible film. As a result, the flexible film isless than form fitted to the molded portion (i.e., the flexible film isloosely fitted to the molded portion resulting in a “wrinkly” or “puffy”appearance). The post-injection molding anneal process alleviates thisproblem by shrinking the flexible film, resulting in greaterform-fitting of the flexible film to the molded portion of thecontainer.

Referring to FIG. 1 shown are schematic diagrams of one example of aflexible container 10 formed of a molded part 20 and a flexible film 30.The flexible container 10 serves to replace areas that would otherwisebe formed of molded material with the flexible film, thereby reducingthe weight of the flexible container 10. Additionally, in specificembodiments of the invention, in which the flexible film 30 is appliedduring the injection molding process and takes the form of pre-cutand/or pre-printed product labels (including product name, logos,graphics, product information and the like), the need for post-injectionmolding handling and processing of the container (e.g., applying aseparate label to the container or the like) is lessened or eliminated.

In the illustrated example of FIG. 1 the molded part 20, which maycomprise polypropylene, polyethylene or the like, includes two apertures22A and 22B, otherwise referred to as opening or holes, which serve asthe areas that would otherwise be formed of molded material and overwhich the flexible film 30 is applied. In the illustrated example, afirst aperture 22A is formed in a first side portion 24A and a bottomportion 26 of the container and a second aperture 22B is formed in asecond side portion 24BA (opposite to the first side portion 26A) andthe bottom portion 26. The first aperture 22A and the second aperture22B being separated in the bottom portion 26 by a bottom molded portion28, which is configured as an I-beam-like separating member. It shouldbe noted that other embodiments of the molded part may include more orless apertures based on such features as the geometric configuration ofthe flexible container, the desired rigidity of the flexible containerand the like.

Further, in the illustrated example of FIG. 1 the flexible film 30,which may comprise a layered laminate of polypropylene or the like, is asingle flexible film that is affixed to the perimeter of the apertures22A and 22B and overlays and is affixed to the bottom molded portion 28.As will be discussed in detail infra., in specific embodiments of themethod of making the flexible container 10 the flexible film 30 isaffixed to the molded part 20 during the injection molding process, suchthat, a back layer of the laminate flexible film comprises atemperature-sensitive polymer that adheres to the molded part during thecuring of the molded material. It should be noted that in otherembodiments of the invention more than one flexible film may beimplemented to form the flexible container based on such features as thesize and location of the apertures, the geometric configuration of theflexible container, the desired rigidity of the flexible container andthe like. Additionally, it should be noted that while embodiments of theinvention herein described provide for the flexible film to be affixedto the molded part during the injection molding process, in otherembodiments of the invention, the flexible film may be affixed to themolded part after completion of the injection molding process (i.e.,once the molded part has been removed from the mold).

Referring to FIG. 2 a flow diagram is present of a method 100 for makinga flexible container, in accordance with embodiments of the presentinvention. The method herein described can, in some embodiments, beperformed by a programmable machine operating under computer processorcontrol.

At Event 110, an injection mold that includes a male die having acentral axis and a corresponding female die is provided. An exemplarymale die is shown and described in FIGS. 3 and 4, infra. At Event 120,the male die is inserted into the female die, such that the insertionprocess defines a space between the male die and female die. The spacebetween the male and female dies is the area that is subsequentlyinjected with the container material to create the molded part.

At Event 130, a movable portion, otherwise referred to as the core, ofthe male die is moved, or otherwise expands, away from the central axisto thereby reduce a volume of the space. In specific embodiments of themethod, movement of the movable portion of the male die serves to reducethe volume of the space such that one or more apertures (i.e., openingsor holes) are created in the molded part. In specific embodiments of themethod, moving the movable portion of the male die is accomplished byclosing the injection mold to affect mechanical movement of the movableportion of the male die away from the central axis. In other embodimentsof the invention, other means of affecting movement of the movableportion, such as pneumatics, hydraulics, or the like, may beimplemented.

At Event 140, container material is injected in the space and thecontainer material is cured to create a molded part having at least oneaperture. In specific embodiments of the method, the container materialmay comprise polypropylene, polyethylene or any other suitable polymericmaterial used in injection molding processing. In other specificembodiments of the method, the molded part is cured at a predeterminedtemperature in the range of about 300 degrees Fahrenheit to about 525degrees Fahrenheit. In specific embodiments of the method, the resultingmolded part has two apertures; a first aperture opening along both afirst side portion and the bottom portion of the molded part and asecond aperture opening along a second side portion (which is oppositethe first side portion) and the bottom portion of the molded part. Themolded part (20) shown and described in FIG. 1 provides for such anexemplary molded part, however, it should be noted that other moldedparts having different configurations, different number of apertures anddifferent aperture configuration are also possible and within theinventive concepts herein disclosed.

At Event 150, the movable portion of the male die is moved, or otherwisecollapses, towards the central axis to thereby increase the volume ofthe space. In specific embodiments of the method, moving the movableportion of the male die towards the central axis is accomplished byopening the injection mold to affect mechanical movement of the movablepart. As previously noted, in other embodiments of the invention, othermeans of affecting movement of the movable portion, such as pneumatics,hydraulics or the like, may be implemented.

At Event 160, the male die is withdrawn from the female die and, atEvent 170, the molded part is removed from the injection mold. It shouldbe noted that implementation of the movable portion of the male die, inwhich the movable portion is moved, or otherwise collapses toward thecentral axis after completion of the injection mold process serves toalleviate reliability problems associated with removing the molded partfrom the injection mold.

At Event 180, at least one film is adhered to the molded part along theperimeter of the one or more apertures. In specific embodiments of themethod, the film(s) are adhered to the molded part during the injectionmolding process. In such embodiments of the method, the film(s) aredisposed in the female die prior to inserting the male die into thefemale die and the curing of the container material results in theadherence of the films to the molded part over the one or apertures(i.e., along the perimeter of the one or more apertures). Further, insuch embodiments of the method, movement of the movable portion awayfrom the central axis serves to hold the films in place during theinjection of the container material and subsequent curing of thecontainer material. In specific related embodiments, the films comprisea multi-layered laminate of polypropylene or the like, in which the backlayer (i.e., the inner layer that is not in contact with the female die)comprises a temperature-sensitive polymeric material that melts andadheres to the molded part in response to curing temperatures.

At Event 190, the flexible container is annealed at a predeterminedtemperature and for a predetermined dwell time to thereby shrink thefilm to form-fit the molded part of the flexible container. In specificembodiments of the method, the predetermined temperature and dwell timeare selected based on one or more of (1) the geometry/size of theflexible container, (2) the thickness and/or width/length of the filmand (3) the amount of shrinkage desired.

Additionally, according to specific embodiments of the method, the filmthat is configured to be adhered to the molded part with a predeterminedaxial grain orientation. Grain orientation of the film is important tothereby affect shrinkage in the desired direction during annealing. Forexample, in the example shown in FIG. 1, in which the film extendslengthwise along two opposite sides of the container, shrinkage isdesired in a lengthwise direction of the films and, as such, the grainsof the film should also be oriented in the same lengthwise direction. Inanother example, in which films are configured on the flexible containersuch that uniform shrinkage is desired across the entire the film(s),the grains of the film should be axial oriented diagonally (i.e.,cross-wise) to accommodate for uniform shrinkage in all directions. Assuch, in those embodiments in which the film is disposed in the femaledie prior to insertion of the male die into the female die, the film isrequired to be properly aligned in the female die to assure the desiredaxial grain orientation of the film. Moreover, in those embodiments inwhich the film includes a product label, the label printing and/or labelcutting process is required to properly align the films so that thelabel appears on the film with the desired axial grain orientation.

Referring to FIGS. 3 and 4, shown are perspective views of an exemplarymale die 200 of an injection mold that is implemented in variousembodiments of the present invention. Specifically, the male die 200 maybe used in a method for making the flexible container shown in FIG. 1.FIG. 3 illustrates the male die 200 having a movable portion 210 in acollapsed state and FIG. 4 illustrates the male die having a movableportion 210 in the expanded state. In the illustrated embodiments ofFIGS. 3 and 4 the moveable portion 210 is a plate that forms anexpandable/collapsible core of the male die 200. It should be noted thatwhile FIGS. 3 and 4 show the movable portion 210 present on the topfacing 220 of the male die, in practice the movable portion 210 is alsopresent in the bottom facing 230 of the male die, as well. In specificembodiments, separate movable portions (e.g., plates or the like) areprovided in both the top facing 220 and the bottom facing 230 of themale die to accommodate movement in both directions.

The collapsed state of the movable portion shown in FIG. 3 exists priorto and after completion of the injection molding and curing operations.In specific embodiments of the invention, movement of the movableportion 210 away from the central axis 240 of the male die 210 occurs inconjunction with the closing the injection mold and results in theexpanded state of the moveable portion shown in FIG. 4. In the expandedstate the movable portion 210 serves to decrease the volume of spacebetween the male die 200 and a corresponding female die (not shown inFIGS. 3 and 4). The decreased volume of space results in aperture(s)being formed in the molded part. Additionally, in those embodiments ofthe invention in which the film is adhered to the molded part during theinjection molding process, the expanded state of the movable portion 210provides for holding the film in place during the injection molding andcuring processes.

Once the injection molding and curing processes are completed, themovable portion 210 of the male die 200 moves toward the central axis240 resulting in the collapsed state shown in FIG. 3. In specificembodiments of the invention, the movement of the movable portion 210toward the central axis 240 occurs in conjunction with the opening ofthe injection mold and results in the collapsible state shown in FIG. 3.As previously discussed, in the collapsed state the flexible containeris more readily removable from the injection mold.

Thus, as described in detail above, present embodiments of the inventionprovide for methods of making flexible containers that implement aninjection mold having a collapsible core that expands/moves to definethe apertures and, in some embodiments, hold the flexible film in placeduring the injection mold process and collapses/moves backpost-injection molding process to allow for the flexible container to bereadily removed from the die. In addition, the method includes apost-injection molding anneal process that is implemented to allow theflexible film to shrink so as to provide for form-fitting of the film tothe molded portion of the container.

Although many embodiments of the present invention have just beendescribed above, the present invention may be embodied in many differentforms and should not be construed as limited to the embodiments setforth herein; rather, these embodiments are provided so that thisdisclosure will satisfy applicable legal requirements. Also, it will beunderstood that, where possible, any of the advantages, features,functions, devices, and/or operational aspects of any of the embodimentsof the present invention described and/or contemplated herein may beincluded in any of the other embodiments of the present inventiondescribed and/or contemplated herein, and/or vice versa. In addition,where possible, any terms expressed in the singular form herein aremeant to also include the plural form and/or vice versa, unlessexplicitly stated otherwise. Accordingly, the terms “a” and/or “an”shall mean “one or more,” even though the phrase “one or more” is alsoused herein. Like numbers refer to like elements throughout.

As will be appreciated by one of ordinary skill in the art in view ofthis disclosure, the present invention may include and/or be embodied asan apparatus (including, for example, a system, machine, device, amobile device such as a mobile phone, a computer program product, and/orthe like), as a method (including, for example, a computer-implementedprocess, and/or the like), or as any combination of the foregoing.Accordingly, embodiments of the present invention may take the form ofan entirely method embodiment, an entirely software embodiment(including firmware, resident software, micro-code, stored procedures ina database, or the like), an entirely hardware embodiment, or anembodiment combining software and hardware aspects that may generally bereferred to herein as an apparatus or as a system. Furthermore,embodiments of the present invention may take the form of a computerprogram product that includes a computer-readable storage medium havingone or more computer-executable program code portions stored therein. Asused herein, a processor, which may include one or more processors, maybe “configured to” perform a certain function in a variety of ways,including, for example, by having one or more general-purpose circuitsperform the function by executing one or more computer-executableprogram code portions embodied in a computer-readable medium, and/or byhaving one or more application-specific circuits perform the function.

It will be understood that any suitable computer-readable medium may beutilized. The computer-readable medium may include, but is not limitedto, a non-transitory computer-readable medium, such as a tangibleelectronic, magnetic, optical, electromagnetic, infrared, and/orsemiconductor system, device, and/or other apparatus. For example, insome embodiments, the non-transitory computer-readable medium includes atangible medium such as a portable computer diskette, a hard disk, arandom access memory (RAM), a read-only memory (ROM), an erasableprogrammable read-only memory (EPROM or Flash memory), a compact discread-only memory (CD-ROM), and/or some other tangible optical and/ormagnetic storage device. In other embodiments of the present invention,however, the computer-readable medium may be transitory, such as, forexample, a propagation signal including computer-executable program codeportions embodied therein.

One or more computer-executable program code portions for carrying outoperations of the present invention may include object-oriented,scripted, and/or unscripted programming languages, such as, for example,Java, Perl, Smalltalk, C++, SAS, SQL, Python, Objective C, JavaScript,and/or the like. In some embodiments, the one or morecomputer-executable program code portions for carrying out operations ofembodiments of the present invention are written in conventionalprocedural programming languages, such as the “C” programming languagesand/or similar programming languages. The computer program code mayalternatively or additionally be written in one or more multi-paradigmprogramming languages, such as, for example, F#.

The various methods described herein may be implemented by one or morecomputer-executable program code portions. These one or morecomputer-executable program code portions may be provided to a processorof a general purpose computer, special purpose computer, and/or someother programmable data processing apparatus in order to produce aparticular machine, such that the one or more computer-executableprogram code portions, which execute via the processor of the computerand/or other programmable data processing apparatus, create mechanismsfor implementing the steps and/or functions described herein.

The one or more computer-executable program code portions may be storedin a transitory and/or non-transitory computer-readable medium (e.g., amemory or the like) that can direct, instruct, and/or cause a computerand/or other programmable data processing apparatus to function in aparticular manner, such that the computer-executable program codeportions stored in the computer-readable medium produce an article ofmanufacture including instruction mechanisms which implement the stepsand/or functions described herein.

The one or more computer-executable program code portions may also beloaded onto a computer and/or other programmable data processingapparatus to cause a series of operational steps to be performed on thecomputer and/or other programmable apparatus. In some embodiments, thisproduces a computer-implemented process such that the one or morecomputer-executable program code portions which execute on the computerand/or other programmable apparatus provide operational steps toimplement the steps described herein. Alternatively,computer-implemented steps may be combined with, and/or replaced with,operator- and/or human-implemented steps in order to carry out anembodiment of the present invention.

While certain exemplary embodiments have been described and shown in theaccompanying drawings, it is to be understood that such embodiments aremerely illustrative of and not restrictive on the broad invention, andthat this invention not be limited to the specific constructions andarrangements shown and described, since various other changes,combinations, omissions, modifications and substitutions, in addition tothose set forth in the above paragraphs, are possible. Those skilled inthe art will appreciate that various adaptations, modifications, andcombinations of the just described embodiments can be configured withoutdeparting from the scope and spirit of the invention. Therefore, it isto be understood that, within the scope of the appended claims, theinvention may be practiced other than as specifically described herein.

What is claimed is:
 1. A method for making a flexible container, the method comprising: providing for an injection mold comprising a male die having a central axis and a corresponding female die; inserting the male die into the female die, wherein the insertion defines a space between the male die and the female die; moving a movable portion of the male die away from the central axis to thereby reduce a volume of the space; injecting a container material in the space and curing the container material to create a molded part having at least one aperture; moving the movable portion of the male die towards the central axis to thereby increase the volume of the space; withdrawing the male die from the female die; removing the molded part from the injection mold; adhering at least one film to the molded part along a perimeter of the at least one aperture; and annealing the container at a predetermined temperature and for a predetermined dwell time to thereby shrink the film to form-fit the container.
 2. The method of claim 1, wherein adhering the film further comprises disposing the film in the female die prior to inserting the male die into the female die and wherein curing the container material additionally provides for adhering the film to the molded part over the at least one aperture.
 3. The method of claim 2, wherein moving the movable portion of the male die away from the central axis further comprises moving the movable portion of the male die away from the central axis to thereby hold the film in place.
 4. The method of claim 2, wherein adhering the film further comprises providing for the film comprising a layered laminate of polypropylene, wherein a back layer of the film comprises a temperature-sensitive polymer that adheres to the container material during the curing of the container material.
 5. The method of claim 1, wherein adhering the film further comprises providing for the film to have a predetermined axial grain orientation to thereby affect shrinkage in a desired axial direction during annealing.
 6. The method of claim 5, wherein providing for the film to have the predetermined axial gain orientation further comprises predetermining the grain orientation based on at least one of (1) a type of film used, and (2) a geometry of the container or the at least one aperture.
 7. The method of claim 1, wherein injecting a container material in the space further comprises injecting the container material in the space, wherein the container material is one of polypropylene or polyethylene.
 8. The method of claim 1, wherein curing the container material further comprises curing the container material at a predetermined temperature in a range of 300 to 525 degrees Fahrenheit.
 9. The method of claim 1, wherein moving the movable portion of the male die away from the central axis, further comprises closing the injection mold to affect mechanical movement of the movable portion of the male die away from the central axis.
 10. The method of claim 1, wherein moving the movable portion of the male die towards the central axis, further comprises opening the injection mold to affect mechanical movement of the movable portion of the male die towards the central axis.
 11. The method of claim 1, wherein annealing the container at a predetermined temperature and for a predetermined dwell time further comprises selecting the predetermined temperature and the predetermined dwell time based on at least one of (1) a size of the container, and (2) a thickness of the film.
 12. The method of claim 1, wherein injecting the container material in the space to create a container having at least one aperture, further comprises injecting the container material in the space to create a container having two apertures, a first aperture opening in a first side portion and a bottom portion of the container and a second aperture opening in a second side portion and the bottom portion, wherein the first side portion is opposite the second side portion.
 13. A method for making a flexible container, the method comprising: providing for an injection mold comprising a male die having a central axis and a corresponding female die; disposing a film in the female die; inserting the male die into the female die, wherein the insertion defines a space between the male die and the female die; moving a movable portion of the male die away from the central axis to thereby reduce a volume of the space and hold the film in place; injecting a container material in the space to create a container having at least one aperture; curing the container material, wherein curing the container material provides for adhering the film to the container material over the at least one aperture; moving the movable portion of the male die towards the central axis to thereby increase the volume of the space; withdrawing the male die from the female die; removing the container from the male die; and annealing the container at a predetermined temperature and for a predetermined dwell time to thereby shrink the film to form-fit the container.
 14. The method of claim 13, wherein disposing the film in the female die further comprises providing for the film to have a predetermined axial grain orientation when disposed in the female die to thereby affect shrinkage in a desired axial direction during annealing.
 15. The method of claim 14, wherein providing for the film to have the predetermined axial gain orientation further comprises predetermining the grain orientation based on at least one of (1) a type of film used, and (2) a geometry of the container or the at least one aperture.
 16. The method of claim 13, wherein disposing the film in the female die further comprises providing for the film comprising a layered laminate of polypropylene, wherein a back layer of the film comprises a temperature-sensitive polymer that adheres to the container material during the curing of the container material.
 17. The method of claim 13, wherein injecting a container material in the space further comprises injecting the container material in the space, wherein the container material is one of polypropylene or polyethylene.
 18. The method of claim 13, wherein curing the container material further comprises curing the container material at a predetermined temperature in a range of 300 to 525 degrees Fahrenheit.
 19. The method of claim 13, wherein moving the movable portion of the male die away from the central axis, further comprises closing the injection mold to affect mechanical movement of the movable portion of the male die away from the central axis.
 20. The method of claim 19, wherein moving the movable portion of the male die towards the central axis, further comprises opening the injection mold to affect mechanical movement of the movable portion of the male die towards the central axis.
 21. The method of claim 13, wherein annealing the container at a predetermined temperature and for a predetermined dwell time further comprises selecting the predetermined temperature and the predetermined dwell time based on at least one of (1) a size of the container, and (2) a thickness of the film.
 22. The method of claim 13, wherein injecting the container material in the space to create a container having at least one aperture, further comprises injecting the container material in the space to create a container having two apertures, a first aperture opening in both a first side portion and a bottom portion of the container and a second aperture opening in both a second side portion and the bottom portion of the container, wherein the first side portion is opposite the second side portion.
 23. A method for making a molded part, the method comprising: providing for an injection mold comprising a male die having a central axis and a corresponding female die; inserting the male die into the female die, wherein the insertion defines a space between the male die and the female die; moving a movable portion of the male die away from the central axis to thereby reduce a volume of the space; injecting a container material in the space and curing the container material to create a molded part having at least one aperture, wherein moving the movable of the male die away from central axis defines the at least one aperture; moving the movable portion of the male die towards the central axis to thereby increase the volume of the space; withdrawing the male die from the female die; and removing the molded part from the injection mold, wherein moving the movable portion of the male die towards the central axis assists in removing the molded part from the injection mold. 